Golf club set

ABSTRACT

Golf club irons having improved forgiveness, playability and performance characteristics are disclosed. The embodiments set forth parameters of various irons that affect performance either alone or in combination with other parameters when the irons are utilized to strike a golf ball. The parameters, which in some cases may be systematically progressed or varied, include golf club shaft length, striking face area, loft, coefficient of restitution, face thickness, topline thickness, swing weight, sole width at the heel and toe, and other performance characteristics.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.12/980,238, filed Dec. 28, 2010, which claims priority to and benefit ofU.S. Provisional Patent Application No. 61/291,294, filed Dec. 30, 2009,both of which are incorporated herein by reference.

FIELD

The present application concerns golf club irons designed to increaseforgiveness, playability and performance.

BACKGROUND

Golf is a game in which a player, using many types of clubs, hits a ballinto each hole on a golf course in the lowest possible number ofstrokes. Golf club manufacturers and designers seek to improve certainperformance characteristics such as forgiveness, playability, feel, andsound. In addition, in sets of golf clubs, such as sets of irons,continuity of the performance characteristics within the set may bedesirable. Golfers prefer golf clubs that exhibit performancecharacteristics such as forgiveness, performance and playability. Onemeasure of “forgiveness” can be defined as the ability of a golf club toreduce the effects of mis-hits, e.g., hits resulting from striking thegolf ball at a less than ideal impact location and manner on the golfclub head. Greater forgiveness of the golf club generally equates to ahigher probability of hitting a straight golf shot. “Playability” can bedefined as the ease with which a golfer can use the golf club iron forproducing accurate golf shots. Better performance of a set of irons canbe defined to include, among other things, increased peak trajectory,ball speed and distance, and/or shot precision.

Thus, there exists a need for a set of irons that improves at least theforgiveness and playability characteristics to provide a golfer withimproved performance, consistency, and confidence.

SUMMARY

The present application concerns golf club irons designed to increaseforgiveness, playability and performance. In one embodiment, the ironshave substantially larger and consistent face areas but progressivelythinner face thicknesses from the wedges or shorter irons to the longerirons. In another aspect, the irons have uniquely wide sole widths ordimensions. In yet another aspect, the shaft lengths are uniquely andprogressively longer from the wedges or shorter irons to the longerirons. These parameters and their overall systematic and uniqueprogressions or variations work individually and together with one ormore other parameters to improve forgiveness, playability, andperformance.

For instance, in one embodiment, the golf set includes ten irons(specifically, 3-iron to 9-iron, PW, AW, and SW) and each iron has aface area greater than 3100 mm². The long irons (i.e., 3-, 4-, and5-irons) have a face thickness of about 1.9 mm, the middle irons (i.e.,6- and 7-irons) have a face thickness of about 2.2 mm, and the shortirons and wedges (i.e., 8- and 9-irons and PW, AW, and SW) have a facethickness of about 2.5 mm. In another embodiment, the 3- through 9-ironshave substantially the same size face area that is greater than about3100 mm², and preferably about 3150 mm². In other embodiments, the ironshave substantially wide sole widths in order to allow (among otherthings) weight to be distributed lower and farther back from the club'sface. The embodiments disclosed herein provide, among other things,irons with higher coefficients of restitution (COR), which in someembodiments is greater than about 0.800 (when tested as set forthherein).

In some embodiments, the topline thicknesses of the long irons are about9.3 mm to about 9.4 mm, those of the middle irons are about 8.5 mm, andthose of the short irons and wedges are about 7.5 mm to about 7.7 mm. Inother embodiments, the 3-iron has a shaft length of about 38.0 inches orgreater, and preferably 38.6 inches, and the 4-iron and 5-iron each havea shaft length of about 37.0 inches or greater, and preferably 37.9 and37.3 inches, respectfully.

It should be understood and appreciated that the parameters and uniquevariations of the irons provide increased club head speed, ball launchangles, higher peak trajectory, and ball speed and distance. As such,the irons allow for more forgiveness and playability for golfers of allabilities.

The foregoing objects, features, and advantages of the golf club set arenot intended to be limiting and will become more apparent from thefollowing detailed description, which proceeds with reference to theaccompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The claimed subject matter is illustrated by way of example and notlimitation in the figures of the accompanying drawings in which likereferences indicate similar elements.

FIG. 1A is a toe-ward view of an embodiment of a golf club head.

FIG. 1B is a face view of an embodiment of a golf club head.

FIG. 2A is a face view of an embodiment of a golf club head.

FIG. 2B is a cross-sectional view of an embodiment of a golf club head.

FIG. 2C is a cross-sectional view of an embodiment of a golf club head.

FIG. 3 illustrates one embodiment of a golf club set.

DETAILED DESCRIPTION

Various embodiments and aspects of the golf club irons will be describedwith reference to details discussed below, and the accompanying drawingswill illustrate the various embodiments. Numerous specific details aredescribed to provide a thorough understanding of various embodiments ofthe claimed subject matter. However, in certain instances, well-known orconventional details are not described in order to provide a concisediscussion of embodiments of the claimed subject matter. In view of themany possible embodiments to which the principles may be applied, itshould be recognized that the illustrated embodiments are only preferredexamples of the golf club irons disclosed herein and should not be takenas limiting the scope of the claimed subject matter. It will be evidentthat various modifications may be made thereto without departing fromthe broader spirit and scope as set forth herein. The specification anddrawings are, accordingly, to be regarded in an illustrative senserather than a restrictive sense.

Embodiments of a golf club set may include performance characteristicsthat may have a particular progression and/or continuity, meaning, forexample, that individual clubs within the set may have particularcharacteristics that vary as compared to other clubs within the set. Inone embodiment, a golf club set may include a plurality of golf clubirons. A standard set may include approximately 8 irons, numbered from3-pitching wedge (PW), although less or more than 8 irons may comprise aset, and embodiments of the claimed subject matter are not limited inthis respect. For example, in one embodiment an iron set may include 10irons, comprising 3-PW, A-wedge (AW) and sand wedge (SW).

A typical set of irons may not take into account the needs of individualgolfers, but, generally speaking, tend to be designed to have a standardprogression of performance characteristics. As a result, one set of golfclub irons may not perform well for all golfers. It may not be practicalfor each golfer to customize a set of irons, as this may be costprohibitive.

Performance characteristics may include characteristics that may affectperformance of a golf club when utilized to strike a golf ball. Inparticular embodiments, performance characteristics may include golfclub shaft length, golf club striking face area, golf club loft, golfclub coefficient of restitution, golf club face thickness, golf clubtopline thickness, golf club cavity volume if the golf club has acavity, golf club swing weight, golf club sole width at the heel and/orat the toe, and other performance characteristics. One or more of theseperformance characteristics may be determined by particular methods,including one or more methods as set forth by current United States GolfAssociation (USGA) regulations.

FIGS. 1A and 1B illustrate a golf club iron head. Illustrated in FIGS.1A and 1B is a golf club head 100, which is an iron golf club head. Golfclub head 100 has a face 102, which has a particular face area and aparticular face thickness. Golf club head 100 includes a toe 106 and aheel 108. Golf club head 100 includes a sole 104 having a width. Thesole width may vary between the toe 106 and the heel 108, although inother embodiments the sole width may not vary. Golf club head 100includes a hosel offset 110 and a loft 114. Golf club head 100 alsoincludes a topline 112 having a thickness. The topline thickness mayvary along the top surface of golf club head 100, although in otherembodiments the topline thickness may not vary. Additionally, golf clubhead 100 may have a particular COR, and when assembled into a golf clubmay have a particular swing weight. Also, golf club head 100 maycomprise a cavity back type of golf club head, and the cavity of thecavity back may have a particular cavity volume.

As mentioned previously, one or more of these characteristics may varybetween golf club heads within a set. Some characteristics may vary morethan others, and the characteristics may follow a linear progression ora non-linear progression. As just an example, in one embodiment thefollowing characteristics may vary between the golf club heads within aset: shaft length; topline thickness; face area; cavity volume; swingweight; sole width at heel and toe; face thickness; loft; and COR.However, as noted previously, the scope of the claimed subject matter isnot limited to just these characteristics, and may include otherperformance characteristics not listed in detail.

Referring now to FIGS. 2A, 2B and 2C, there are illustrated multiplegolf club heads. Illustrated in FIG. 2A is a golf club head 200, whichis an iron golf club head. Golf club head 200 has a face 202, which hasa particular face area and a particular face thickness. Golf club head200 includes a toe 206 and a heel 208. Illustrated in FIG. 2B is a golfclub head 220. Golf club head 220 includes a sole 204 having a width.The sole width may vary between the toe area and the heel area, althoughin other embodiments the sole width may not vary. Golf club head 220includes a topline 212 having a thickness. The topline thickness mayvary along the top surface of golf club head 220, although in otherembodiments the topline thickness may not vary. Additionally, golf clubhead 220 may have a particular COR, and when assembled into a golf clubmay have a particular swing weight. Golf club head 220 includes a face214 having a thickness 216. Furthermore, golf club head 220 comprises ahollow area 218. As will be explained later, hollow area 218 may befilled with materials including polymer and/or foam, and when includedas part of a golf club set, the hollow area as well as the fillermaterials may vary from club to club. Illustrated in FIG. 2C is a golfclub head 230. Golf club head 230 includes a sole 232 having a width.The sole width may vary between the toe area and the heel area, althoughin other embodiments the sole width may not vary. Golf club head 230includes a topline 224 having a thickness. The topline thickness mayvary along the top surface of golf club head 230, although in otherembodiments the topline thickness may not vary. Additionally, golf clubhead 230 may have a particular COR, and when assembled into a golf clubmay have a particular swing weight. Golf club head 230 includes a face228 having a thickness 226. Furthermore, golf club head 230 comprises acavity back area 222 having a particular volume. As will be explainedlater, when included as part of a golf club set, cavity back area 222may vary in shape and/or volume from club to club within the set.

Referring now to FIG. 3, there is illustrated a golf club set 300. Golfclub set 300 may include one or more types of golf club heads 304,including cavity back, muscleback, blades, hollow clubs or other typesof club heads typically used as part of a set. Golf club set 300 mayhave varying performance characteristics between clubs. For example,shafts 302 may vary in length, swing weight may vary, and one or more ofthe performance characteristics noted above may vary. As one example, atleast a portion of the golf clubs of set 300 may include hollow clubs.Individual hollow clubs may include hollow areas that vary in volume.Furthermore, hollow areas may be filled with foam, polymer or othertypes of materials, and the particular type of filler materials may varyfrom club to club. Additionally, the club types within set 300 may vary,such as by including some hollow clubs, some cavity back clubs and somemuscleback clubs within one set.

Table 1 illustrates one particular preferred embodiment of a golf clubset having performance characteristics that vary between clubs withinthe set. However, it is worthwhile to note that this is just oneembodiment and the claimed subject matter is not limited in thisrespect.

TABLE 1 Iron # 3 4 5 6 7 8 9 PW AW SW Shaft length 38.6 37.9 37.3 36.736.0 35.5 35.1 34.5 34.5 34.3 (inches) Topline 9.4 9.3 9.4 8.5 8.5 7.67.6 7.5 7.5 7.7 thickness (mm) Face Area 3152 3152 3152 3152 3152 31543150 3166 3207 3348 (mm²) Swing Weight D3.5 D3.5 D3.5 D3.5 D3.5 D3.5D3.5 D3.5 D3.5 D5.0 Sole Width, toe 25.5 26.1 26.5 24.9 25.2 23.4 23.823.8 24.8 26.0 (mm) Sole Width, 17.5 17.9 18.4 18.4 19.0 18.1 18.5 19.019.3 21.3 heel (mm) Face thickness, 1.9 1.9 1.9 2.2 2.2 2.5 2.5 2.5 2.52.5 base (mm) Loft (degrees) 19 21 24 27 31 35 40 45 50 55 COR measured.819 .807

As reflected in Table 1, there is a unique progression in increasedshaft lengths from the SW to the 3-iron. (It should be understood thatthe golf club set may have fewer or more irons as set forth in Table 1.)A club head's speed (as the club is swung) correspondingly increaseswith an increase in the club's shaft length. Greater club head speedequals greater ball speed and hence distance. It is generally preferableto achieve a consistent average gapping distance from club to club. Inthis way, the golfer is provided with a full range of consistent andincreasing club shot distances so that the golfer can select a club oriron for the distance required by a particular shot or situation.Typically, the average gapping distance from club to club in a set ofirons for an average player is about 8-10 yards. As set forth herein,the uniquely increased shaft lengths from the SW to the 3-iron helpprovide for an average gapping distance for an average player of about11-15 yards from club to club, respectively. In this respect, theembodiments herein provide consistency as well as an overall greaterrange of distances for the golfer.

The overall increase in shaft length from the SW to the PW is about 0.2inches. As such, the increase in club head speed from the SW to the PWis not as substantial as each club is similarly swung. However, otherphysical parameters of the wedges, including for instance the degree ofloft as set forth in Table 1, influence the average shot distance foreach such wedge. The increase in shaft length from the 9-iron to the3-iron is more substantial than the increase in the shaft lengths of thewedges. As such, the increase shaft lengths in this respect result inrespective increases in club head speed and hence greater ball speed anddistances. It should be appreciated that such shaft lengths and theiroverall progression from club to club are unique. For instance, theshaft length of the 3-iron is about three-fourths of an inch longer thanthe typical 3-iron. The average golfer has more difficulty hittinglonger irons, such as a 3-iron or 4-iron. As a result, the averagegolfer using a typical set may not hit the 3-iron or 4-iron as long as a5-iron. However, in the embodiment set forth in Table 1, the longershaft lengths of the irons, such as the 3- and 4-irons, alone and inconjunction with other parameters as set forth herein, result in greaterclub head and ball speed than in typical golf sets. Thus, in this way,the average golfer may consistently hit the 3-iron farther than the4-iron and the 4-iron farther than the 5-iron, for instance.

Another parameter contributing to overall greater gap distance in theset, and greater ball speed and distance for each individual iron, isface thickness. A thinner face thickness provides a higher coefficientof restitution (COR). It should be understood that a higher CORgenerally correlates to a greater launch speed of a golf ball uponimpact with the club face, and hence greater ball flight distance. Asset forth in one embodiment reflected in Table 1, the face thickness isbasically consistent from the SW to the 8-iron or about 2.5 mm. The facethickness substantially decreases from the 8-iron to the 3-iron, or fromabout 2.5 mm to about 1.9 mm. Specifically, as set forth in Table 1, theface thickness of the 6- and 7-irons is about 2.2 mm, and the facethickness of the 3-, 4- and 5-irons is about 1.9 mm. This uniqueprogression of thinner face thicknesses increases the COR of the clubsin the longer irons, alone and in conjunction with other parameters asset forth herein.

Thinner face thicknesses also allow more weight to be distributed alongthe perimeter of the club face and/or lower and farther back from theface of the club, thereby providing for higher moments of inertia (MOI)and more forgiving “sweet spot” areas. This allows the face area to beincreased while not increasing or significantly increasing the club'sweight or swing weight. As reflected in Table 1, the face area of the3-iron through the 9-iron is substantially the same, and is above about3100 mm², or preferably from about 3152 mm² to about 3150 mm². The facearea of the PW is also substantially the same at about 3166 mm².Typically, the face area of the 3-iron is smaller than that of a PW byabout 300 mm² or more, but that is not the case in the embodimentreflected in Table 1. And the face areas of the AW and SW are about 3207mm² and about 3348 mm², respectively.

Thus, the larger faces of the clubs, especially in conjunction withthinner faces, provide for increased COR (or “trampoline” effect) and“sweet spot” areas. In other words, the clubs are more forgiving if theball is not struck in the center of the face or at the ideal spot sincethe larger face area in turn provides for a larger area for the ball tobe struck and still achieve satisfactory trajectory, speed and flightdistance. As shown in Table 1, the COR can be above 0.800. The CORfigures set forth herein are measured first by impacting the iron with aball travelling at 133 ft/sec (per USGA protocol for irons) andmeasuring the COR. A ball is then impacted with a calibration plate at133 ft/sec and the COR is measured. (The calibration plate is calibratedto represent a COR of 830 for a driver when impacted with a balltravelling at 160 ft/sec.) The difference in COR values between the ballimpacting the iron at 133 ft/sec and the calibration plate at the samespeed is calculated. That numerical value is then used to estimate theCOR for a ball strike on the iron at 160 ft/sec (taking into account theCOR is 830 for the calibration plate at that speed), and that estimateis recorded as the COR value of the irons as reflected herein.

As reflected in Table 1, the topline thickness progression of the clubsincreases substantially from the SW to the 3-iron. In particular, thetopline thicknesses of the wedges and short irons (or SW, AW, PW, and8-, 9-irons) range from about 7.5 to about 7.7 mm. The topline thicknessof the middle irons (or the 6- and 7-irons) is about 8.5 mm. The toplinethicknesses of the long irons (or the 3-, 4-, 5-irons) are from about9.3 to about 9.4 mm. It is believed that a thinner topline visuallymakes a club appear more difficult to hit or requires more precision instriking the ball. Thus, the increased topline thicknesses of the longand/or middle irons give the appearance that these clubs are easier tohit than such clubs having thinner topline thicknesses. Golferstypically have more difficulty hitting longer and middle irons thanshorter irons or wedges. Thus, thicker topline thicknesses on longand/or middle irons build a golfer's confidence that he or she canproperly or effectively hit such irons with success. The wedges andshort irons have thinner topline thicknesses since these clubs typicallyare easier to hit than long and/or middle irons, and golfers tend to hitthem with more precision than the other irons. Likewise, the thinnertoplines of the shorter irons and wedges also give the player moreconfidence that she or he can hit such irons with the precision oftenrequired of them. (It should be appreciated of course that precision isalso often required by middle and long irons.)

As shown in Table 1, the swing weight of the irons is essentiallyconsistent from club to club. Consistent swing weight contributes to aconsistent feel for the golfer to the extent possible from club-to-club.A consistent feel and balance of the clubs increases the likelihood thatthe golfer will produce a consistent and repeatable swing, and thus gainconfidence, independent of the club selected for a particular shot.

Another unique feature of one embodiment of the golf club set whenconsidered individually and in conjunction with the other parameters isthe width of the soles, both at the toe and heel of each club head.Specifically, the parameters discussed herein allow for more weight tobe distributed lower and farther back in the club head relative to theface of the club. This allows for increased launch angles, therebylaunching golf balls higher more quickly and faster and increasingoverall peak trajectory and distance. Traditional club sets generallyprogress in sole widths (especially at the toes) from the long irons tothe wedges, with the long irons particularly having much thinner soles.As reflected in Table 1, the longer irons, such as the 3-, 4-, and5-irons, have relatively wide sole widths at the toes that allow (amongother things) more weigh to be distributed lower and farther back in theclub head. The long irons are relatively wider in this respect comparedto the other irons in the set. As with the long irons, the other clubsin the set have unique sole widths to also provide the performancecharacteristics mentioned above. It should be understood that shorterirons and wedges in particular have higher loft angles so wider solewidths are somewhat secondary factors in achieving increased launchangles. As set forth in Table 1, the progression of loft degree of theclubs increases from the 3-iron through the SW. It should be appreciatedthat increased loft angle increases launch angle and the peak trajectoryof the golf ball, and that the other parameters as discussed herein workin conjunction with the loft angles of the clubs to improve performance,playability and forgiveness.

In view of the many possible embodiments to which the principles of thedisclosed embodiments may be applied, it should be recognized that theillustrated embodiments are only preferred examples and should not betaken as limiting the scope of the claimed subject matter. It will beevident that various modifications may be made thereto without departingfrom the broader spirit and scope set forth herein. The specificationand drawings are, accordingly, to be regarded in an illustrative senserather than a restrictive sense.

1. A set of golf club irons, comprising: at least three irons whereinthe irons have topline thicknesses that progress from about 7.5 mm for ashorter iron in the set to about 9.4 mm for a longer iron in the set. 2.The golf club set of claim 1 wherein the clubs have shaft lengths thatprogress from about 34.5 inches for a shorter iron in the set to about38.6 inches for a longer iron in the set.
 3. The golf club set of claim1 wherein the set has 3-, 4- and 5-irons with sole toe widths from about25.5 mm to about 26.5 mm.
 4. The golf club set of claim 1 wherein theclubs have a face area of greater than about 3100 mm².
 5. The golf clubset of claim 4 wherein the set includes a 3-, 4-, 5-, 6-, 7-, 8- and9-iron and wherein said irons have a face area of substantially the samesize.
 6. A set of golf club irons, comprising: at least three ironswherein the irons have face thicknesses that progress from about 1.9 mmfor a longer iron in the set to about 2.5 mm for a shorter iron in theset.
 7. The golf club set of claim 6 wherein the clubs have shaftlengths that progress from about 34.5 inches for a shorter iron in theset to about 38.6 inches for a longer iron in the set.
 8. The golf clubset of claim 6 wherein the clubs have topline thicknesses that progressfrom about 7.5 mm for a shorter iron in the set to about 9.4 mm for alonger iron in the set.
 9. The golf club set of claim 6 wherein theclubs have a face area greater than about 31 00 mm².
 10. The golf clubset of claim 9 wherein the clubs have a face area of substantially thesame size.
 11. A set of golf club irons, comprising at least three ironswherein the irons have shaft lengths that progress from about 34.5inches for a shorter iron in the set, the shorter iron being one of apitching wedge and a 9-iron, to about 38.0 inches for a longer iron inthe set, the longer iron being one of a 2-iron, a 3-iron, and a 4-iron.12. The golf club set of claim 11 wherein the set has 3-, 4- and 5-ironswith sole toe widths from about 25.5 mm to about 26.5 mm.
 13. The golfclub set of claim 11 wherein the set has 3-, 4- and 5-irons each havinga face thickness of 1.9 mm.
 14. A set of golf club irons, comprising: a3-, 4-, 5-, 6-, 7-, 8-, and 9-iron, wherein said irons each have a facearea of substantially the same size and greater than about 3100 mm2 andwherein the 3-, 4-, and 5-irons each have a face thickness of about 1.9mm, the 6-iron and 7-iron each have a face thickness of about 2.2 mm,and the 8-iron and 9-iron each have a face thickness of about 2.5 mm.15. The golf club set of claim 14 wherein the irons each have a facearea of about 3152 mm².
 16. The golf club set of claim 14 wherein theset further includes at least a SW, AW or PW having a face thickness ofabout 2.5.
 17. The golf club set of claim 16 wherein the SW, AW or PWhas a face area greater than about 3100 mm².
 18. The golf club set ofclaim 14 wherein the 3-, 4-, and 5-irons each have a shaft lengthgreater than about 37.0 inches.
 19. The golf club set of claim 14wherein the 3-iron has a shaft length of about 38.6 mm, the 4-iron has ashaft length of about 37.9 mm, and the 5-iron has a shaft length ofabout 37.3 mm.
 20. The golf club set of claim 14 wherein two of saidirons have a coefficient of restitution greater than 0.800.